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Summary of Contents for IDEAL Concord CX40
- Page 2 CAUTION. To avoid the possibility of injury during the installation, servicing or cleaning of this appliance care should be taken when handling edges of sheet steel components. Concord CX - Installation...
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Page 3: Gas Controls
It is in your own interest, and that of safety, to ensure that the law is complied with. Fault Finding..............30 The Concord CX40/100 range of boilers has been tested and Gas Safety Regulations ........... 3 certified by British Gas to prEN656 for use with Natural gas only. -
Page 4: Number Of Sections 3
GENERAL Table 1- Performance Data Boiler CX 40 CX 50 CX 60 CX 70 CX 80 CX 90 CX 100 Number of sections Boiler Input Nett 47.3 56.3 67.7 79.2 90.7 102.3 112.6 Btu/h (x 1000) 161.4 192.1 230.9 270.3 309.6 349.0 384.2... -
Page 5: Electrical Controls
GENERAL DUTY Control is by a slow opening combination gas control incorporating a thermocouple flame failure device and mains voltage gas valve. The range of boilers is suitable for: Combined indirect pumped The control box has a terminal plug connection for mains input. domestic hot water and central heating systems;... -
Page 6: Clearances & Dimensions
GENERAL Graph 1 - Heat load / water volume Graph 2 - Hydraulic Resistance CLEARANCES & DIMENSIONS Table 3 Boiler Size CX 40 CX 50 CX 60 CX 70 CX 80 CX 90 CX100 No. of sections Front clearance mm (in) 750 (29 Rear clearance mm (in) -
Page 7: Pump
GENERAL achieved either by provision of an adequate bypass circuit or PUMP POSITIONS by ensuring that a zone of suitable size is open for Whenever practically possible the circulating pump(s) should be circulation during this period by relevant control of zone positioned so that it pressurises the system being served. -
Page 8: Installation Requirements
GENERAL INSTALLATION REQUIREMENTS 1mm of lime reduces the heat transfer from metal to water by 10%. The appliance must be installed by a CORGI ( ) registered installer. In practice the deposition of these salts is liable to cause noises from the boiler body or even premature boiler failure. The installation of the boiler must be in accordance with the relevant Corrosion and the formation of black iron oxide sludge will requirements of the Gas Safety Regulations, current I.E.E. -
Page 9: Air Supply
GENERAL FOUNDATION CHIMNEY SYSTEM The boiler must stand on a non-combustible floor (i.e. concrete To ensure the safe and satisfactory operation of the boiler the or brick) which must be flat, level and of a suitable load bearing chimney system (which may be common or individual, in the capacity to support the weight of the boiler (when filled with case of twin or multiple boiler installations) must be capable of water) and any ancillary equipment. -
Page 10: Installation
INSTALLATION CONCORD CX BOILER ASSEMBLY - Exploded view Legend 13. Section bolt 7. Drain cock 1. Cleanout cover 14. Distribution tube 8. NOx duct 2. Collector hood 15. Tie rods 9. Front plate 3. Middle section 16. Thermostat pocket 10. Burner manifold assy. 4. - Page 11 INSTALLATION PACKAGING Check that all these packages are complete and have been INSTALLATION HARDWARE PACK contains: correctly received on site. • M10 washer ........4 off Factory assembled boilers are despatched from the works as fully packaged units comprising: • Split pin ..........
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Page 12: Boiler Assembly
INSTALLATION BOILER ASSEMBLY 1. Fit the distributor tube (supplied with the boiler) into c. Fit the 2 thermostat pockets. Refer to Frame 9. one of the return connections. That is one of the rear Note. Frame 9 shows the relationship between the lower ports - refer to Frame 5. -
Page 13: Flue Connection
INSTALLATION 10 FLUE CONNECTION 11 GAS CONNECTION 1. Connect the gas 1. Complete the flue connection. supply to the gas inlet pipe at the 2. The boiler is designed to accept flues to rear LH side of the BS. 835 and should be sealed with an boiler. - Page 14 INSTALLATION 13 CASING ASSEMBLY - continued 4. Fit 3 clips to the top of each side panel. 5. Fit the spire clips to the side casing panels. 6. Hook on the control box to the side panels. Screw in self tapping screws at the bottom of the control box to fix it to the side panels.
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Page 15: Electrical Connections
INSTALLATION 14 ELECTRICAL CONNECTIONS Connection must be made in a way that allows The internal wiring of the boiler control box is shown in complete isolation of the electrical supply - such as a Frame 15. double pole switch, having a 3mm (1/8") contact Wiring should be in four core PVC insulated cable, not separation in both poles, or a plug and socket serving less than 0.75mm... -
Page 16: Internal Wiring
INSTALLATION 15 INTERNAL WIRING LEGEND b blue br brown y yellow g/y green/yellow v violet bk black w white or orange pk pink 16 ZONES WITH BI-DIRECTIONAL MOTORISED VALVES IMPORTANT Terminal L2 may control the appropriate pump(s) directly, provided that the total running or starting current does not exceed 6A (resistive or inductive): if this rating would be exceeded then appropriate... - Page 17 INSTALLATION 17 ZONES WITH INDIVIDUALLY PUMPED ZONES (3 zones shown) IMPORTANT Terminal L2 may control the appropriate pump(s) directly, provided that the total running or starting current does not exceed 6A (resistive or inductive): if this rating would be exceeded then appropriate switchgear must be used to control the pumps indirectly.
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Page 18: Commissioning And Testing
INSTALLATION 19 COMMISSIONING AND TESTING GENERAL TESTING FOR GAS SOUNDNESS Check that all drain cocks are closed, that any stop valves Close the gas supply cock at the meter. fitted to the flow and return pipes are open and that the Remove the screw in the inlet pressure test point (Frames system has been filled and properly vented. -
Page 19: Gas Pressure
INSTALLATION 21 INITIAL LIGHTING CX 70, 80, 90 AND 100 1. Switch off the electricity supply to the boiler. 8. If the pilot cannot be established, check that the pilot burner flame correctly envelops the thermocouple tip by 2. Press down and release the red button (4) marked * on the 10 - 13 mm ( "). -
Page 20: Spillage Check
INSTALLATION 23 SPILLAGE CHECK 24 TESTING Check that the main burner responds correctly to manual Check there is no spillage of combustion products on/off operations of any controls fitted in the gas control circuit. Check, in the following manner, the operation of the from the boiler draught diverter by carrying out a flame failure safety device: spillage test, as detailed in BS. -
Page 21: Servicing
SERVICING 27 SERVICING Caradon Plumbing Limited does not accept any liability Pull off the igniter lead at the igniter. The centre burner may resulting from the use of unauthorised parts or the repair now be removed by pushing it back to clear the injector and and servicing of appliances not carried out in accordance lifting it out. -
Page 22: Pilot Burner
SERVICING 28 SERVICING - continued 6. The pilot burner head is clean and undamaged. 7. Carefully remove the push-on connections to the overheat thermostat, noting their positions, and clean the thermostat spade connections with steel wool. Re-assemble in reverse order, remembering to reconnect the overheat thermostat interrupter leads and connections in the correct positions - refer to diagram. -
Page 23: Piezo Unit
SERVICING 29 REPLACEMENT OF COMPONENTS - Refer to Frames 5, 24, 36 and 37. GENERAL To facilitate the replacement of components, remove and WARNING. Always turn OFF the gas supply at the gas replace the lower front panel, NOx duct and the burner front inlet cock and switch OFF and DISCONNECT the plate as necessary -described under ‘Servicing’. -
Page 24: Gas Control Valve
SERVICING 34 GAS CONTROL VALVE 35 MAIN BURNER 1. Remove the NOx duct and burner front plate, as previously 1. Undo the thermocouple and pilot gas pipe described in Frame 27. connections at the gas control valve. Disconnect the interrupter leads to the overheat thermostat. 2. -
Page 25: Overheat Thermostat
SERVICING 37 BURNER AND CONTROLS ASSEMBLY - Exploded View CX 70 - 100 LEGEND Overheat thermostat Piezo spark generator Gas inlet union Main gas inlet cock Gas control valve Main (end) burner, 2 off Main (centre) burner, 1 off Main injector, 3 off Gas inlet manifold 10. -
Page 26: Control Sensor
SERVICING 40 CONTROL BOX - Basic Boiler, Exploded View Detail of Printed Circuit Board Support LEGEND Wiring clamp. Connection box plug. Connection box. Terminal strip. Back panel. Printed circuit board 'No. 6A'. Printed circuit board 'No. 1C'. Water temperature control sensor lead. -
Page 27: Combustion Chamber Insulation Replacement
SERVICING 42 PC BOARD ‘NO. 6A’ 43 PC BOARD ‘NO. 1C’ 1. Remove the lower front panel. 1. Remove the lower front panel. 2. Slacken the 2 screws securing the control box front 2. Slacken the 2 screws securing the control box front panel. -
Page 28: Tools Required
SITE ASSEMBLY 45 INSTRUCTIONS FOR SITE ASSEMBLED BOILERS Legend TOOLS REQUIRED 10. Burner manifold assy. 1. Cleanout cover. Spanners 11. Base plate. 2. Collector hood. Torque wrench 12. Combustion chamber. Pozi screwdriver 3. Middle section. Mallet 13. Section bolt. 4. Section alignment 14. - Page 29 SITE ASSEMBLY 46 INSTRUCTIONS FOR SITE ASSEMBLED BOILERS - continued PREPARATION OF SECTIONS Each section should be brushed clean on all external surfaces and any debris which may have accumulated within the section should be removed via the bottom ports. Section assembly - refer to exploded view, Frame 45 6.
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Page 30: Fault Finding
FAULT FINDING Before attempting any electrical fault finding ALWAYS carry the following checks MUST be repeated: out the preliminary electrical system checks as detailed in the Earth continuity Instructions for the British Gas Multimeter or other similar commercially available meter. Polarity The preliminary electrical system checks are the FIRST Resistance to earth... - Page 31 FAULT FINDING 49 PILOT LIT BUT NO MAINS GAS Check the setting of the room thermostat and the cylinder thermostat Have you confirmed that the system controls Check the control system are calling for heat ? Check the supply voltage, e.g. by using a multimeter, set on the 300 V AC range, between Is there a supply voltage at the input plug the L and N terminals.
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Page 32: Short List Of Parts
SHORT LIST OF PARTS The following are parts commonly When ordering spare parts please quote: required as replacements, due to damage 1. Boiler model or expendability. 2. Boiler serial no. (refer to the data plate on the combustion chamber) 3. Boiler B.G. P.I. No. (refer to the data plate on the combustion chamber) Their failure or absence is likely to affect the safety and/or performance of this 4. - Page 33 SHORT LIST OF PARTS Key No. Description Qty. Product No. Right hand jacket side panel - white stove enamel CX 40 111 650 CX 50 111 651 CX 60 111 651 CX 70 111 652 CX 80 111 652 CX 90/100 111 653 Left hand jacket side panel - white stove enamel CX 40...
- Page 34 For details of courses please ring: ....01270 413 624 November 1999 111 303 A06 Ideal Installer/Technical Helpline: 01482 498376 Concord CX - Installation...
- Page 35 Your feedback and your chance to win a free boiler At Ideal we've been leaders in the design and engineering of robust and reliable boilers for over 90 years. We want to continue as leaders by listening to your suggestions for how to improve our boilers and our service.
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Page 36: Further Information
Further information If you would like information about Ideal Boilers please complete this sheet and fax it to us on 01482 498699 or post it to Caradon Plumbing PO Box 103, National Avenue, Kingston upon Hull, HU5 4JN. Installer details...
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